UNIC HYDRAULIC CRANE MODEL UR1500 SERIES WORK SHOP MANUAL FURUKAWA UIC corroremon HEAD OFFICE: Cone Bip, 3-72, Hgatohnapene 2 ome, WMUR1500199902A PRINTED INJAPANINTRODUCTION ‘This technical instruction manual describes the construction of the UNIC UR1500-Series crane and mainte: nance procedures for the servicemen engaged in its maintenance. Please carefully read the manual to acquire the proper maintenance skills and provide efficient, speedy, cor- rect services that are essential to customer trust. In this way, UNIC truck crane will be able to deliver their ‘superb performance and be kept in satisfactory operating condition. Itis recommended that separate pars list be referred to together with this manual Technical Section, Service Department FURUKAWA UNIC CORPORATIONCONTENTS. §1. GENERAL VIEW... §2. PERFORMANCE... §3. BOOM ASS'Y. 1) Telescoping mechanism of boom §4. COLUMN .. §5. BASE §6, TELESCOPING CYLINDER 1) Construction. §7. DERRICKING CYLINDEI §8. OUTRIGGER CYLINDER 1) Horizontally extending cylinde 2) Vertical outrigger cylinder. §9. SLEWING DEVICE. 1) Slewing lock mechanism. 2) Caution to be taken when re-assembling slewing reduction gear §10, REDUCTION GEAR FOR SLEWING 1) Construction... 2) Points to be noticed when assembling reduction gear.. §11. SWIVEL JOINT... §12. SLIP RING 1) Construction of slip ring and where it is mounted §13. HYDRAULIC CIRCUIT DIAGRAM. §14, CONTROL VALVES 41) For hoisting, telescoping, and derricki 2) For controlling slewing and outrigger. § 15. TROUBLES AND MEASURES TO BE TAKEN 1) Crane will not be operated at al 2) How to operate when in an emergenc 3) Adjusting procedures for unloading valve.. 4) Solenoid valve of unloading mechanism... §16. VALVES 1) Main relief valve (RT15C) — STD specification. 2) Outrigger cylinder (Construction of pilot check valve). 3) Rear-outrigger cylinder (Construction of pilot check valve) 4) Horizontally extending cylinder (Construction of check valve)§17. ELECTRIC CIRCUIT DIAGRAM 1) Electric wiring diagram, 2) Electric wiring. §18. CONTROL. 1) Crane controls. 2) Outrigger control §19. REAR OUTRIGGER. 1) Connecting the high-pressure hose for rear outrigger §20. MOUNTING THE HOOK.. §21. MAINTENANCE SECTION 4) Periodic maintenance / Monthly 2) Periodic maintenance / Annual 3) Periodic maintenance / Replacement of expendable part 4) Periodic maintenance / Weekly... § 22. OTHERS 1) Recommended grese .. 2) Recommended gear oil 3) Recommended hydraulic ol§1. GENERAL VIEW No, Description No. Description 1 [Boom 14g | Selector lever Tor controling vertical or 2 Column horizontal outriggers (Street side) 3 | Base 76 | Selector lever for controling verical or horizontal rear outriggers (Curb side) aia [est wach = {7 | Selector lever Tor controling vertical or [5 [Swing device horizontal rear outriggers (Street side) & | Topping cylinder 18 | Hook block 7 | Telescoping cylinder 19 | Accelerator pedal @ [Outrigger 20 | Waming horn 9 [ Boom topping control lever 2i_| Engine switch (START/STOP) 0_| Winch control lever 22 | Emergency release switch 11 | Boom telescoping control lever 23 | Wire rope 12 | Swing control lever 24 | Boom angle chart 13_| Lever to control outiggers forextension/eraction | [25 | Rear outrigger {4 | Selector lever Tor controling vertical or horizontal outriggers (Curb side)§2. PERFORMANCE CRANE CAPACITY LIFTING CAPACITY SHEAVE HEIGHT WORKING RADIUS 800M Boom Length; Boom Telescoping Cylinder; Boom Extending Speed; Boom Raising Cylinder; Boom Raising Speed; JIB (option) vib Length; WINCH Single Line Pull Single Line Speed Lo: Hi; Hydraulic Motor Downhaul Weight; Hook Block (option); Wire Rope Construction; Diameter x Length; Breaking Strength; Max. 30000 Ibs. at 4 t. Max. 113.6 kN (13620 kgf} at 1.22 m with 4-parting of loadiine, Max, 9.12 ft, 115.1 ft. (with 24 ft jib) Max. 27.8 m 36.1 m (with 7.3 m jib) Max. 80.4 ft. Max. 24.5m 4-section box beam type telescoping boom 251. 108.2 7.62 m to 25.0 m Double acting type with counter balance valve 57 1/63 sec, 17.38 m/63 sec. Double acting type with counter balance valve “10° to 82°/16.2 sec. 2-section manual pullout 18 ft. to26 Ht. 4.57 mo 7.32 m Hydraulic motor driven, planetary gear reduction with automatic ‘mechanical brake. 8700 ibs. at 1st layer 38.7 KN (3950 kgf} at 1st layer 112 FPM at 3rd layer 34.0 mimin at 3rd layer 223 FPM at 3rd layer 68.0 m/min at 3rd layer Trochoid type 9400 Ibs. Capacity 41.8 KN (4260 kgf} Capacity 30000 Ibs. Capacity, 3 sheaves block with latch 193.6 KN (13620 kgf) Capacity, 3 sheaves block with latch 6 x WS (31) IWRC 9N6 in. x 236 tt 14mx72m 33920 Ibs. 151 KN (15400 kgf}‘SWING; ‘Swing Range ‘Sewing Speed: Hydraulic Motor, OUTRIGGERS; Vertical Jacks, Horizontal Beams; Outrigger Span: REAR OUTRIGGERS; Vertical Jacks: Horizontal Beams; Rear Outrigger Span: HYDRAULIC SYSTEM; Control Valve; ‘System Pressure; Hydraulic Pump; System Flows Winch; Boom; Swing: Hydraulic Reservoir TOTAL CRANE WEIGHT; SAFETY DEVICES; Hydraulic motor driven, worm and spur gear reduction with worm self locking brake ‘360° continuous rotation on a ball bearing race. 1.44pm Trochoid type Vertical jacks and horizontal beams. Double acting hydraulic cylinders with pilot-operated check valves Double acting hydraulic cylinders with pilot-operated check valves 7AM 1018.7 t 2.26 mto5.7 m Vertical jacks and horizontal beams Double acting hydraulic cylinders with pilot-operated check valves Double acting hydraulic cylinders with pilot-operated check valves 7.411. 011.5 ft 2.26 mto3.5m Multiple control valve, spring centered, speol-type, with pressure reliet valve. 2850 PSI (All functions) 19.61 MPa (200 kgf/cm} (All functions) -seetion gear pump 26.4 GPM 100L/min 26.4 GPM 100L/min 12.7 GPM 48Umin ‘at pump 2000 rpm 50.2 gallons capacity 190 liters capacity 11950 tbs. 5425 kgt + Capacity Alert System (Capacity Alert System is not functional when lifting with jb.) + Anti Two-Block System + Outrigger Motion Alarm * Over-tront Alarm Note: The figures in relation to the speed are on the basis of no-load running at rated oll flow conditionsore tet ? Reiger sre sone on ASS¥ WOO ESNwnI09 °»5api in nt 6 Fa wa ERE asva ss(wauizeozs) w9'6e ew (Paiunow oye (wuzEza)uPa Oz} (wuuZEza)uLTOR VIR {paunow seye exons (wo6zs)u6'at) axons (WWOOSS NEL (reo-go) SATA FONVIVEESINTOO uonanasuog (1 ~9-Suyqui9sse uoym a1eq 98eBIB MBBY $$$ — none (uungauZz at m yuanaid OL (@oeid 1) pauel¥BN oeq Sey PUES JoWe apis puet® premoy i PuSe YAGNITAD ONDIOINHAG *2§ =10—‘axons (aNUsZZI)UTS “TewooyonieN) Wag 7 sJepuriAo Buipuayxa AyrequoziioH (1 YAGNITAD YSDDIYLNO 8S =‘rou ase) (42q19801 HOLL HOT Bussn £9 young) ‘pauan4BH udBq sey 1 J9Yye G 1AqUUMU HOS Jo mosDs peay 9420s UOREXAY 34} punose sadeUd Z YUNA 'Z (1110. 1907140} sted uaBe une a98 Be @ s2qusnw wos yo smotas peoy 194208 os x9y ay1 SuUNYBN 210}99 LOLZH.LHOUL NOOT AWEY “1 (e10n) @ me -12e- [sien a) (wamasOOTNET | ge eee Jepuljho 1966) ano jeoMen (Zaes / =13- Suioq au uaryB 0% 2964 40 2924 LHOLL 901 {(uy6x)p=s9(sqyu)o'6se-z'Lyp} anbioy Bur “@osxz2nv (101) woa Pi AOIAIG ONIMATS 6 §1) Slewing lock mechanism Built-in hydraulic motor for slewing lock When PTO is engaged, hydraulic motor starts to produce back pressure by the check valve mounted between the puinp No.3 and the control valve. This releases the lock mechanism being built in che hydraul c motor automatically When PTO is disengaged on the other find, slewing is to be locked automatically by the spring builtin the hydraulic motor CONTROL VALVE / os J, 7 [PUNIP Noa PUMP No.2 ®) Location of check valve and its construction | CONTROL VALVE (CHECK VALVE REDUCTION GEARS FOR SLEWIN HYDRAULIC MOTOR PE Pay attention to the marking direction =14- + From pump —+ To lock cylinder2) Construction of hydraulic motor for slewing lock mechanism PORT B(clockwise) Q [ora port ht Tightening torque: 16 otMb9(2.5kst-m) X i PF14-19 \ Pilot port \ (counterclockwise) LJ \PORT Alcounterclockwise) Tightening torque:18.0fvIbs(2.5kst-m) bron) HYDRAULIC MOTOR) ma} +o RAIN PORT i ee | EXTERNAL PILOT PORT Tightening torque (/Taa-14 GRIMS Tightening torque "144-14 6hlbs(2.0-2.3KgiTm) oc§10. REDUCTION GEARS FOR SLEWING 1) Construction WORM SHAFT | — ‘TAPER ROLLER BEARING | \CROWN NUT GEAR SHAFT TC TAPER ROLLER BEARING DUST SEAL BEARING HOUSING BREATHER —S5 BALL BEARING/ -16—2) Caution to be taken when re-assembling slewing reduction gear 1} Places to be applied ssansuarr 7 T | _busT SEAL: Apply “Three Bond #1401" tt Fill up with grease here. “Use lithium soap radical grease (such as Rizonix grease No.1 of JOMO) ‘Note: Tighening torque 7-3. fUibs(10.5 — Cd ® Apply grease to the inside of lip of dust seal directed upward WORM WHEEL -17-§11. SWIVEL JOINT Full up-grease (chassis grease) when assembling. SS (DDERRICKING = ~f[pp-—- { (RAISE) @ TELESCOPING -£5 (exTEND) ‘@ TELESCOPING (RETRACT) 5 HoIsTING--|}~ (uP) ‘® HoIsTING (own) Full up grease when assembling. -18—§12. SLIP RING 1) Construction of slip ring and where it is mounted AVO.85WX3.9ft(1200mm) (White) \e = / \ oy ® @® caP(Femate)| | CAL a Apply “LOCK TGHT #242" before tightening he philips pan head screw, 5 CAPMALE) -) [ne 8 82700 (Red) AVO.BSBX4.1f(1270mm) (Black) AVO.85HX 4.2ft(1300mm) AWAY eS aS SSS -18-psi en sonmva crundtaonttasaene Or A) er WvHOVIG LINdUIO TINVEGAH “e15a NaNVL 3a OL S3UNSVW ONY S3TENOULa [asics \s i | am LO Ole OP Lp foua6sowe ve w wou orerodo 01 MoH (21 4m Hoa ou 0} Un 9 > BL OH ESE Hr Hog a Uo4) Solenoid valve of unloading mechanism Coil resistance(9.95:5% 9) ‘SOLENOID ASS'Y(Type:S2V-101-DC-12:31) NUT(Tightening torq {tVIbs(2-3kg/m) | STOP VALVE! STOP VALVE(Tightening torque T=21.€-36.11¥bs(2-Skg/m) 9 Where to check the stop valve STOP VALVE Com. eCheck to see if; © Check if O-ring (8568-012) in section @ has not been broken, © Check ino foreign substances have been stuck in the top of spool on the por @) -26—(How it works) 1) When in normal crane work Gil Mowing feom the port P is blocked by the spool as illustrated so that it ean not flow into the tank port 2 When in automatic stop ‘When in an automatic stop, iron core of the solenoid allows the spool to shift to the left to link holes between the sleeve and! the spool ‘As a result, oil from the port P flows into the tank port as illustrated. ‘SPOOL, SLEEVE -27—§ 16. VALVES 1) Main relief valve (RT15C) STD specification Main relief valve functions to prevent oil pressure in the hydraulic circust from going beyond the specified. (1) Construction of Relief Valve LOW PRESSURE MAINSPRING ROUTE HIGH PRESSURE / mainvatve — \oRIFICE (2) How to Adjust Relief Valve il pressure isto be set by how far the adjustment bolt has been screwed in Remove the cap and unfasten the nut to adjust the oil pressure Turning the bolt clockwise with a screw driver fing into the slot in the bolt end in rning it counterclockwise decreases the pressure es the oil pressure and Remove the cap to loosen the nut, @ Toming te bol clockwise with a screwdriver increas es the pressure and turning it counterclockwise decreases the pressure -28—@ Set the pressure while monitoring pressure gauge with any one ofthe cylinders (for outrigger, telescoping, or derrick) retracted Relief pressure to be set 2500 psi "Do not set the pressure with the engine idling or running at high speed, but set the pressure with the engine running the pump at the rated speed. @ Lock the nut (M10) with spanner while Fixing the sot in the bolt end with a screwdriver as the adjusiment bolt may be loose wten tightening the nut and the ep ‘SPANNER SCREWDRIVER (3) Where In relief valve are to be checked ‘When pressure fails o rise, check the relief valve as illustrated below, 3 4 Foreign substances being stuck in section @® and valve seat surface, O-ring ® for damage ARP568-012 H570 (PIN: 731473012} O-ring © for damage P15 Hs90 (P/N: 731491015) Foreign substances being stuck in drilled hole of section ©. Foccign substances being stuck in section(€) and valve seat surface. Note : If anything has not been found wrong with the above, suspect the hydraulic pump. -29-2) Outrigger cylinder (Construction of pilot check valve) PILOT CHECK VALVE (For extension) (For retraction) / TuBE ASs'Y. Type (CP-02RA) 3) Rear-outrigger cylinder (Construction of pilot check valve) PILOT CHECK VALVE. TUBE ASS'Y (For extension) ion) PILOT CHECK VALVE (Type:CP-03F) ‘For ret -30—4) Horizontally extending cylinder (Construction of check valve) | come |) =31- ‘Type (CP-02P)817, ELECTRIC CIRCUIT DIAGRAMa_— enum ors oe ea 15) OULNOD 8151) Crane controls With the dual operator contol station the UNIC CRANE can be operated on either side of the nit. The cons fn the base are: boom rise, Hoist, telescope and boom swing, engine aecelerator and outrigger system. All con- trols and direction of uctwation for Jesited movement are identified by the information placard mounted on control knobs counterclockwise “eEL oy aan 4 & SS > : a, To rotate To retract To hoist clockwise boom, hook ‘Swing lever Boom telescoping lever LR Hook hoisting lowering lever Boom topping lever ‘Accelerator pedal Boom To raise boom, move lever to pull ‘To lower boom, move lever 10 pUSh. Hoist ‘To hoist hook, move lever to pull; To lower hook, move lever to push. Extension —- To extend boom, move lever to push; ‘To retract boom, move lever to pull Swing To rotate boom clockwise, move lever to Pull: To rotate boom counter-clockwise, move lever to push Accelerator = Foot operated with factory adjusted stop for maximum pump speed of 2000r. p.m Note : Controls must be used together to achieve combinations of movements. For instance, the boom extension and loadline (hoist) must be used together to maintain clearance between boom tip and hook block. ~36-2) Outrigger controls 1. Stand clear of outtiggers 1 avoid crushing injury. 2. Do not operate ouitiggers without determining clearance from obstructions or personne! 3, Never lower or raise any outrigger unless you or the signal person assisting you can see the outrigger shoe and the ground where the outrigger will make contact and can confirm the area is clear ofall personnel. 4. Fu: lute to follow this procedure may result in a serious crushing injury to workmen, property damage, or crane instability Rear outrigger venies (Curb side) euagee Rear outrigger even) (street side) area Front outrigger Berton, (curb side) Vertical outigger Front outrigger (Selection) venient Tetuer siggy Ve — (Saecton) (Selection) selection lever Outriggers : To exend curigger cylinder move lever w push ‘To retract outrigger cylinder, move lever to pull Selection To select vertical fronvrear outrigger cylinder, move lever to push; To select horizontal fronucear outrigger cylinder. move lever to pull -37—519, REAR OUTRIGGER, el Tee ioo 4s9661n0 480110) oy ounssoxdayBiy a4) BundoUUOD (b§ 20. MOUNTING THE HOOK (1) Pull out wire stowly from drum. Pass wate cope under the boom, and tum it around the right sheave of boom tip as view From the base ~40-(2) Pass wire through wire socket in the direction shown in the figure. Note: Pay also attention to the position of weight ass'y. 2 PART LINE 1 PART LINE a 3 PART LINE 4 PART LINE Ke LOADS UPTO LOADS UP TO LOADS UP TO LOADS UP TO (3) Pass wire through wire socket in the direction shown in the figure. 9N6 inwire rope —_ wire clip wedge wire socket ya YY (4) Fit the wire socket either to the hook or to the boom tip. Oo =a§21. MAINTENANCE SECTION 1) Periodic maintenance / Monthly (1) Lubricate swing bearing Use chassis grease. fe sure fill grease ino the bearing from the erease zak Do not mov the crane while itis being lubricated, (2) Check gear oil levet WINCH SYSTEM |. Remove te oil level plug, 2. Fill oil up to the standard level 3. Install the oil level plug. | Oil level plugSWING SYSTEM 1. Remove the vent plug for Filer por. 2. Remove the il level plug, 3. Fill oil up to the standard level 4. Install the oi! level plug and the vent plug, ~ A, out ievel plug {| Remove the cover Standard level.2) Periodic maintenance / Annual (1) Change hydraute oi ‘ZX CAUTION] Hot oil and components can cause injury. Do not allow hot oil or components to contact skin. Drain the oil only when engine is stopped and the oil is cool. Filler port 1 Prepare a sufficient container. The amount required for a change is about 190 Lit(50.2 gal.) 2. Remove the hydraulic oil reservoir filler cap. 3, Remove the drain plug and drain the hydraulic ei 4 Remove the four bolts to remove the cover. Take the suction strainer out of the tank 5. Clean the suetion strainer in a non-flammable solvent, Replace the strainer, if tis damaged, 6, Flush the tank with non-flammable solvent 7 Install suction strainer and install the drain plug. 8. Alter supplying oil, tighten the cap securely by hand,(2) Change return filter + The return filter should be changed after 3 months of initial operation, and once a year thereatter. |. Turn the retum filter counter-clockwise to remove and discard the element. I the filter is hard to loosen, use the filter weeneh 2. Cleun the filter base, Lubricate oil to the packing for new filter and then screw in and tighten with all your sirength, (3). Start-up check |. Hydraulic oil tank level check Check that hydraulic oil level is between the marks indicating upper and lower limits on the oil level gauge “which is attached on the side ofthe oil tank. Conditions of checking + Retum the crane to its orginal position to set the vehicle ina state ready for running, + Insest level gauze until cap contacts oil filler, pull out level gauge, and check oil level ‘Check oil level on the oil level gauge attached on the side of oil tank. Upper limit Level gauge Lower limit —45—(4) Change gear oll {for winch gear box and swing gear box + The gear oll should be changed after 6 months of initial operation, and once a year thereafter Hot oil and components can cause injury. Do not allow hot oil or components to contact skin. WINCH SYSTEM L Remove the oil level plug, 2.Remove the drain plug Install the drain plug 3Remove tie oil level plug and the oil filler plus. 4 Fill new oil up to the standard level nol Sulnstall the oil level plug and the filler plug. SWING SYSTEM [Remove the drain plug and drain oil Install the drain plug 2.Remove the vent plug for filler port. 3.Remove the oil level plug 4.Fill new oil up to the standard level 5.Jnstall the oi! level plug and the vent plug. ae(5) Checking swing bearing mounting bolts When the device of this machine gives out unusual noise during operation or traveling, or when a gap is produced on the mounting surface, contact our authorized service shop for repair ing. -47—3) Periodic maintenance/Replacement of expendable parts Replace the following pans periodically in order that the stength and quality ofthe original machine may be main tained When you replace the above parts, contact UNIC CORPORATION or the authorized dealer. Replacement parts Replacement intervals | Boom wear pads every 3 years Packings, id Dust-seals for tel linder, top- very 3¥e a ackings, O-rings and Dust-seals for telescoping cylinder, top: —— ing cylinder, and outrigger cylinder. oS4) Periodic maintenance / Weekly LUBRICATE THE FITTINGS ‘Thoroughly clean grease nipples before lubrication. When supplying grease into a bushing, be sure 10 pump the grease gun until old grease is forced out of the busking Applications Lubricant Procedure ten Molybdenum grease Brush Boom foot pin Chassis grease Grease gun Topping cylinder upper support pin ‘Chassis grease Grease gun 7 | Topping cylinder lower support pin Chassis grease =) «Grease gun — © | Rotation gear teeth Chassis grease Brush ® | Wire rope Rope grease Spray ~49—§ 24. OTHERS 1) Recommended grease (1) Chassis grease Use NLGI No, I grate [ Pettoieum Maker Brand SSO ‘Chassis grease L Tosi HP221 CALTEX | Mulifak EPL SHELL “RETINAX-CD (1) Molybdenum grease Use NEGI No. 2 grade Petroleum Maker Brand SSO, Beacon Q2 MOBIL Mobilplex Special [ CALTEX Molytex Grease ‘SHELL Retinax AM) 2) Recommended gear oil (a) SWING SYSTEM Use API Service GL-4 gear oils. Petroleuin Maker Brand | Esso ‘Standard gear oi] 90 MOBIL ‘Mobilube SAE 90 Universal Thuban SAE 90 SHELL ‘Shell Spirax EP 90 (b) WINCH SYSTEM Use API GL.-2/3 gear oll or equivalent. Petroleurn Maker Brand TEXACO MEROPA 150 so3) Recommended hydraulic oil Use industrial-1ype hydraulic oi 180 VG 46 for most temperatures. 180 VG 32 extremely low temperatures Brand Petroleum Miaker —____ 10 VG 32 180 VG 46 85 UNVICE 132 Teresso 46 MOBIL, Mobil DTE 13 “| Mobil DTE 25 CALTEX Rando Oil HD AZ32 Rando Oil 46 I Stet ‘Shell Tellus Oil 32 hell Tellus Oil a6 —si-FURUKI Ua ete sees org HEAD OFFICE : Center Bidg., 3-12, Higashishinagawa 2-chome, Shinagawa-ku, Tokyo 140, JAPAN